Zebra Flex Technical Specifications

Payload Capacity: Up to 75 kg total, with sturdy shelves supporting heavy loads (each shelf can hold 25–30 kg depending on height positioning).  The robot’s low centre of gravity and secure shelf design allow safe transport of loads up to ~88 cm (34.6″) high.

Base footprint of 52.8 cm x 61.1 cm (20.8″ x 24.1″) (W x L), making it compact enough for narrow aisles and dense warehouse layouts. Two form-factor heights are available: a standard (~137 cm tall) or an extended configuration (~150 cm tall) for additional shelf capacity​.

Moves at up to 1.75 m/s (3.9 mph) to keep pace with fast picking operations. It can pivot in place (zero turning radius) for excellent maneuverability in confined areas​.  This agility allows FlexShelf to navigate tight warehouse aisles and reposition quickly during picks.

The base FlexShelf focuses on core transport functionality. It is equipped with dynamic LED light bars along the shelf supports which serve as pick-to-light indicators, illuminating to show pickers where to place or retrieve items​. These multicolour LEDs can indicate task status or priority and improve accuracy during picking and put-away. In the standard FlexShelf configuration, there is no built-in touchscreen (to streamline the robot for operations using handheld or voice devices), but the platform does include a 4-port USB hub and available power for adding peripherals. For example, operations can attach a tablet, scanner or label printer if needed​.

Despite its simplicity, the FlexShelf AMR is a powerful aid in warehousing workflows. It supports both each picking and batch picking models with ease – workers can pick directly into totes on the robot (pick-to-tote) or use it for batch picking multiple orders concurrently. It’s also effective for interleaving picking and replenishment, where the same robot that helps pick orders can also carry inventory for restocking shelves on return trips.  This model is often used in goods-to-person transport: for instance, shuttling picked orders to packing stations or moving inventory between zones. In summary, the FlexShelf provides the fundamental hardware for robotic picking workflows: a modular shelving system on a smart, self-driving base that dramatically improves picking productivity by reducing the distance human workers need to walk

One 10-inch class touch display with multi-language support for operator instructions, mounted at an ergonomic height. The screen is high-brightness and can be used with gloves.

1D/2D barcode imager for scanning product barcodes or location QR codes during picks, and an NFC/RFID reader for user authentication and potential scan of RFID-tagged inventory​.

Same multi-colour LED strips as FlexShelf (upright beams and possibly additional indicators) for pick/put guidance and status alerts. These work in concert with the touchscreen to direct the picking process visually​.

Wi-Fi 6 (802.11ax) connectivity ensures rapid communication with the fleet management system and WMS. There are also I/O ports (Ethernet, USB, DisplayPort) on the base for expansion or maintenance access. The robot’s onboard compute can interface with external devices via the provided USB hub (up to 8 auxiliary USB ports available when one screen is in use) for custom peripherals (e.g. a portable printer to print labels at the point of pick)​.

Same 9-hour nominal runtime on lithium battery, with autonomous opportunity charging. The added electronics (screen/scanner) draw from the robot’s power system but are efficiently managed; the overall runtime remains ~9 hours as with FlexShelf.

FlexShelf: Carries shelves and uses LED indicators for guidance, but no built-in touchscreen or scanner (designed to pair with external devices or for simpler transport tasks).

FlexShelf Guide (FlexGuide): Adds a built-in user interface (1× touchscreen, scanner, NFC) on one side for integrated picking guidance on the robot.

FlexShelf Guide Dual: Provides dual-sided interfaces (2× touchscreens, scanners, NFC) for two-sided picking operations​.

Zebra Symmetry and the underlying FetchCore cloud software come with open APIs and pre-built connectors to common warehouse and manufacturing systems. The Flex AMRs can integrate seamlessly with Warehouse Management Systems (WMS) and Warehouse Execution Systems (WES) – for example, systems like Manhattan Associates, Blue Yonder, or SAP – as well as Manufacturing Execution Systems (MES) on the production side. This integration allows robot workflows to be triggered by real warehouse orders and inventory movements. For instance, when an order drops into the WMS, the system can automatically dispatch a FlexShelf robot to assist a picker with fulfillment of that order. Conversely, when a picker scans an item on the robot, that confirmation can immediately update the inventory in the WMS. By bridging the gap between physical movements and digital systems, the Flex Series acts as a catalyst for end-to-end warehouse automation.

Symmetry also supports integration with Enterprise Resource Planning (ERP) systems for use cases beyond picking – such as delivering components to a production line just-in-time (MES integration) or moving finished goods to staging based on ERP-driven production schedules. All integration is secured and managed through a cloud or on-premise environment, with IT-friendly features (compliance with Wi-Fi security, user authentication, etc.). Notably, all Fetch AMRs operate on existing Wi-Fi networks, avoiding the need for special infrastructure. This makes deployment simpler and allows the robots to be treated as just another client on the enterprise network, communicating with the central orchestration software.

Zebra Symmetry (and FetchCore) provide advanced capabilities like: 

Fleet Management: A unified console to monitor all robots, assign tasks, and view status. Fleet scheduling algorithms ensure the right robot is sent to the right job at the right time, optimising utilisation. Symmetry can dynamically allocate work to robots based on priority (e.g., urgent orders) and even orchestrate multiple robots and workers in a picking wave with assignable priorities for tasks. 

Human-Robot Collaboration: The software guides human associates as well as robots. For example, it can push instructions to a robot’s touchscreen (for the picker) and simultaneously send notifications to a worker’s wearable device. This ensures both parties “always know their next assignment,” operating in lockste. The outcome is a balanced workload where neither robots nor humans are left idle – a concept Zebra refers to as dynamic orchestration of robots and humans​

Workflow Library: Common workflows (like order picking, replenishment, pallet transport, sortation, etc.) are provided out-of-the-box. Users can drag and drop to configure these or create custom flows. For example, a pick-to-tote with automatic conveyor transfer can be set up whereby a FlexShelf collects picked totes and then meets a conveyor drop-off point where another robot (or fixed conveyor) takes over. Such hybrid workflows are configured in the software with logic for hand-offs.

Analytics and Optimisation: Symmetry/FetchCore gathers granular data on robot travel, picks per hour, dwell times, etc. It offers analytics dashboards (including heatmaps of pick locations, throughput charts) to identify bottlenecks. Features like wave management allow grouping of orders into efficient picking runs, and warehouse annotation lets operators map logical zones or storage locations onto a digital map, so the system understands the layout without needing physical QR markers. This means if you re-slot inventory (move items around), the system can adjust navigation and task plans automatically – a big plus in dynamic environments.

Integration of Other Tech: Being part of Zebra’s ecosystem, Symmetry readily integrates the robots with handheld scanners, voice picking systems, and vision systems that workers might already use. For example, a worker could use a Zebra wearable scanner to scan a barcode and the Symmetry platform would record it just as if the robot’s scanner did. This compatibility ensures that introducing the robots doesn’t force a completely new tech stack – it complements existing tools and can leverage Zebra’s extensive data capture and automation portfolio (from mobile computers to smart cameras).

Zebra offers the Flex robots with flexible deployment models as well. Customers can purchase the robots outright as capital equipment or opt for a Robotics-as-a-Service (RaaS) model. Under RaaS, the robots and software are provided on a subscription basis, which can lower the upfront cost and allow scaling the fleet up or down during peak seasons. This approach, supported by Symmetry’s cloud-based nature, means warehouses can rapidly expand their robot workforce during holiday peaks and then scale back, paying only for what they use. Such flexibility in procurement, combined with the integration and orchestration capabilities, positions the Zebra Flex Series as a future-proof investment for warehouse automation.

In e-commerce and retail fulfillment, FlexShelf robots often serve in goods-to-person workflows. Rather than workers walking aisles for each order, the Symmetry software orchestrates FlexShelf/Guide robots to travel to storage locations, where associates pick required items and place them on the robot. The robot then delivers the collected items to a packing station or consolidation area (goods-to-person), reducing picker travel by up to 60%. This is particularly effective in online order fulfillment, grocery picking, and any high-SKU-count environment where walking time dominates. The pick-to-light and put-to-light features of the FlexGuide variants enhance these workflows by speeding up item sortation for multi-line orders. During peak seasons, operators can quickly onboard temporary staff, who can be productive within hours using the intuitive robot-guided picking interface (significantly lowering training time).

The FlexShelf’s multi-bin capacity makes it ideal for batch picking strategies. A worker can pick items for multiple orders in one pass through the warehouse (placing each item into a different tote on the robot’s shelves). The LED indicators and screen ensure each item goes into the correct tote (i.e. order), enabling batch picking without confusion. Once the robot has a batch of orders, it can drive to a sorting area or packing station. This workflow is common in 3PL and distribution centres to maximise picks per trip. The new FlexShelf robots offer 67% more capacity (e.g. more bins per robot or larger totes) than many previous-generation picking AMRs, allowing more orders to be consolidated in one run

Processing returns (common in e-commerce and retail) can be streamlined with FlexShelf AMRs. When items come back to a warehouse, a FlexShelf can be dispatched to carry returned goods from the receiving station to the returns processing or quarantine area. If an item needs to be put back into stock, the robot can even bring it to the appropriate storage aisle for an associate to place on the shelf. Using the robot in returns handling reduces the need for workers to push carts of random returned items around. Additionally, the integrated scanner on FlexGuide models can scan return labels or condition codes, providing immediate feedback on where each returned item should go (back to inventory, to repair, etc.). This workflow benefits 3PLs and e-com warehouses dealing with high volumes of returns, improving efficiency and traceability of returned stock.

In smaller footprint urban fulfillment centers (MFCs) and dark stores, space is at a premium and demand can be unpredictable. The compact size and agility of the FlexShelf robots make them well-suited for automation in these tight spaces. They can navigate narrow aisles (down to ~95 cm in non-worker areas) and coordinate with human pickers in hybrid store environments. A micro-fulfilment operation for grocery, for example, might deploy FlexShelf Guides to quickly pick online grocery orders across a mini-warehouse set up in the back of a retail store. The robots handle the heavy lifting of multiple grocery totes, while staff focus on picking freshness-sensitive items – a collaboration that speeds up order fulfillment. Because the Flex robots require no permanent infrastructure, an MFC can be set up rapidly in an existing space, and even moved or reconfigured if the site changes. This portability and quick deployment align with the needs of pop-up fulfillment sites and experimental retail models.

Across all these use cases, a common theme is that the Flex Series AMRs bring a new level of flexibility and responsiveness to material handling. Workflows that once were fixed (by conveyor belts or rigid automation) or inefficient (entirely manual) can be reengineered with these mobile robots to be lean, adaptive, and easily scalable. Whether it’s improving the each-pick rates in an online retail warehouse or ensuring the right parts are at the right assembly station just in time, the Zebra FlexShelf and FlexGuide robots serve as a reliable backbone for modern intralogistics.

Safety is paramount in any automation that shares space with human workers, and the Zebra Flex Series is built with comprehensive safety and navigation technology. The robots navigate autonomously using a combination of sensors and algorithms that allow them to perceive their environment, avoid obstacles (stationary or moving), and interact safely with people and equipment.

Sensor Suite: Every Flex Series AMR is equipped with a multi-modal sensor array:

A front-mounted 2D LiDAR (laser sensor) with a range of up to 25 m (82 ft) and a 220° field of view scans the environment at ground and pallet height. This laser is typically a SICK safety LIDAR, which creates a planar map of obstacles and is used for both navigation and safety stop functions. The wide coverage helps the robot detect obstacles around corners and as it turns.

Dual 3D depth cameras are mounted on the robot (usually at different heights or angles) to detect obstacles that the 2D laser might not catch – for example, overhanging objects, low-lying obstacles, or the legs of warehouse racks. These cameras provide point-cloud data enabling the robot to “see” in three dimensions and assess situations like a tote protruding from a shelf or an unexpected object on the ground in its path.

LED signal lights not only guide picking but also serve as status indicators (for example, they can flash to signal a stop or error state). Additionally, some floor-projecting lights are used to announce the robot’s presence (e.g., a blue light on the floor ahead of it) which is common in AMRs to alert nearby pedestrians of an approaching robot.

UltraSLAM™ Navigation: The Flex Series employs Zebra/Fetch’s UltraSLAM™ navigation technology for mapping and localizationzebra.com. SLAM (Simultaneous Localization and Mapping) allows the robot to build a map of the facility and pinpoint its own location in real-time, without needing external markers or magnetic tape. UltraSLAM likely fuses data from the 2D LiDAR, 3D cameras, and wheel odometry to achieve robust localization even in dynamic, changing environments. This means the robots can navigate warehouses with moving people, forklifts, and reconfigured layouts reliably. For example, if a new pallet is placed in an aisle, the robot’s sensors will detect it and the UltraSLAM system will update the map or navigate around it on the fly. The “Ultra” aspect suggests enhanced capability – possibly high-precision mapping and the ability to handle very large facilities with many robots concurrently. It also implies the system can adjust to changes (like the warehouse annotation feature that accounts for re-slotting of inventory shelves without needing manual remappingbusinesswire.com). The end result is that Flex robots can be deployed quickly (map the facility once and go) and do not require reflectors, barcodes on the floor, or wires – their navigation is free-form and flexible.

Human Safety and Certifications: All Flex Series robots are designed to be intrinsically safe around humans. They comply with international safety standards for AMRs, notably ANSI/RIA R15.08 in the US, which is a rigorous standard for industrial mobile robots defining how they should detect obstacles, limit forces on impact, have emergency stop functions, etc. They also carry the CE mark, indicating conformity with EU safety directives for machinery. The robots are programmed to yield to humans – if a person steps out in front of a moving FlexShelf, the robot will slow down or stop well in advance using its laser sensing. The typical safety stopping distance and deceleration are tuned to meet or exceed standards, preventing any contact under normal operation. The robots also have audible warnings and status sounds via built-in speakers (4× 10 W speakers). For instance, they may play a gentle chime when starting to move after being stopped or use spoken warnings if a person is too close, configurable per site safety policies.

A particularly innovative safety feature introduced by Zebra is the forklift detection capability – an industry-first for AMRs. Using the onboard sensors, the system can identify forklifts (and presumably their forks) and adjust its behaviour to avoid forklift blind spot. Forklifts can be unpredictable obstacles in warehouses, and their drivers have limited visibility. The Flex robots can detect an oncoming forklift and either pause or reroute to prevent crossing in front of it, significantly reducing the risk of accidents. This forklift detection is an example of how the Flex Series goes beyond basic safety, addressing real-world warehouse scenarios.

Navigation Behavior: The robots are intelligent in path planning – they will dynamically reroute if an aisle is blocked and can cooperate as a fleet to prevent traffic jams. The minimum aisle width for a single robot in operation is about 95 cm (just enough clearance), but when working alongside humans (“fulfilment mode”), Zebra recommends wider aisles (~1.8 m) so that a person and robot can comfortably work side by side or pass each other. In two-way traffic scenarios (multiple robots), the system manages spacing and can use behaviors like “stop-and-go” or “follow-the-leader” to avoid deadlocks in narrow corridors (sometimes referred to as no “leapfrogging” zones, meaning robots won’t try to overtake each other in tight aisles). All these behaviors are governed by the fleet management software’s logic and the robots’ local sensors.

The Flex Series robots are also ADA-compliant for facility use, meaning they can handle ADA standard ramps (though limited to about 3% incline per specs) and they contribute to a safer workplace for workers with disabilities by taking over strenuous transport tasks.

Zebra’s FlexShelf and FlexGuide robots are engineered to navigate autonomously but cooperatively in busy operations, using advanced sensing (LIDAR, 3D vision) and mapping (UltraSLAM) to move efficiently. They actively protect humans and infrastructure through multi-layered safety features, and they meet the highest industry standards for mobile robot safety. These capabilities give businesses confidence that even as they automate, they are not introducing new hazards – the robots operate as cautious, aware vehicles that enhance overall workplace safety while boosting productivity.